The invention relates to a rotating construction laser (1), in particular a self-compensating construction laser. The construction laser (1) comprises a base (2,115) and a laser unit (3,114) for emitting a laser beam (11,83) rotating around an axis (18) of rotation so that the rotating laser beam (11,83) defines a laser plane. Therein, the laser unit (3,114) is built and tiltably arranged to the base (2,115) in such a way, that the axis (18) is tiltable in at least one direction. Furthermore, a tilt sensor (19,96,109) is present for measuring the tilt of the axis (18). According to the invention, the tilt sensor (19,96,109) is supported by a sensor platform being pivotable with respect to the laser unit around the axis (18) between at least two defined pivoting-positions (54,55,70-22) in such a way, that the tilt of the axis (18) is measurable by the tilt sensor (19,96,109) in the at least two pivoting-positions (54,55, 70-22).
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1. A rotating construction laser, comprising:
a base;
a laser unit for emitting a laser beam rotating around an axis of rotation so that the rotating laser beam defines a laser plane, wherein the laser unit is built and tiltably arranged to the base in such a way, that the axis is tiltable in at least one direction; and
a tilt sensor for measuring the tilt of the axis, wherein the tilt sensor is supported by a sensor platform being pivotable with respect to the laser unit around the axis between at least two defined pivoting-positions in such a way that the tilt of the axis is measurable by the tilt sensor in the at least two pivoting-positions.
14. A method for determining a tilt for an axis of rotation of a rotating construction laser, the rotating construction laser comprising:
a base;
a laser unit for emitting a laser beam rotating around the axis so that the rotating laser beam defines a laser plane, wherein the laser unit is built and tiltably arranged to the base in such a way, that the axis is tiltable; and
a tilt sensor for measuring the tilt of the axis, wherein the tilt sensor is pivotable with respect to the laser unit around the axis between at least two defined pivoting-positions, the method comprising:
measuring the tilt by the tilt sensor in each of the at least two pivoting-positions; and
deriving the tilt value for the axis by considering the measurements taken by the tilt sensor in the at least two pivoting-positions.
2. A rotating construction laser according to
3. A rotating construction laser according to
4. A rotating construction laser according to
5. A rotating construction laser according to
a calculation unit being designed in such a way, that:
a tilt value for the axis is derived by considering a measurement taken by the tilt sensor in each of the at least two pivoting-positions; and/or
the tilt sensor is calibrated, or re-calibrated, by considering a measurement taken by the tilt sensor in each of the at least two pivoting-positions.
6. A rotating construction laser according to
7. A rotating construction laser according to
8. A rotating construction laser according to
9. A rotating construction laser according to
10. A rotating construction laser according to
11. A rotating construction laser according to
12. A rotating construction laser according to
13. A rotating construction laser according to
15. A method according to
16. A method according to
17. A method according to
18. A method according to
19. A method according to
20. A method according to
21. A method according to
22. A method according to
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Rotating construction lasers are well known in the prior art. For example, in U.S. Pat. No. 7,370,427 a construction laser with at least one laser beam defining a plane is described. The construction laser has a laser unit that is tiltable relative to a housing around at least one swiveling axis. The construction laser includes at least one leveling sensor which is sensitive to the swiveling axis for a highly precise orientation to the gravitational field. The device further includes one tilt sensor which is sensitive to the swiveling axis for direct measurement of an inclination angle relative to the gravitational field.
Disadvantageous in this embodiment is that a level sensor and a tilt sensor are needed to perform the tilt measurement with an acceptable degree of accuracy. Furthermore, the laser beam unit periodically needs to return to its level position for recalibrating the tilt sensor.
Likewise, WO 2008/052590 A1 relates to indicating a grade, e. g. in construction applications, using a laser beam. The laser beam is emitted from a laser unit to a desired direction having a grade angle with regard to the level angle. A level sensor is provided for adjusting the level angle and a grade sensor is provided for indicating a grade angle on the basis of the level angle from the level sensor.
This device also requires two sensors to correctly indicate the grade.
According to U.S. Pat. No. 5,485,266, fixed tilt detectors are fixed in planes crossing perpendicularly to each other of a shaft center of a laser projector, and tilting tilt detectors are mounted on a plate which is tiltable with respect to the shaft center of the laser projector. The laser projector is level in such a manner that the fixed tilt detectors indicate horizontal direction. The tilting tilt detectors are aligned with the fixed tilt detectors and indicate a horizontal direction. Thus, a horizontal reference plane is obtained. The tilting tilt detectors are tilted with the fixed tilt detectors as a reference and the laser projector is leveled so that the tilting tilt detectors indicate horizontal direction. Thus, a reference plane tilted at an arbitrary angle is obtained.
This device also requires multiple tilt sensors.
As can be seen from the prior art, two tilt sensors are usually used for measuring the tilt of an axis of rotation of a rotating construction laser with high accuracy. One of these sensors is a level sensor which is of very high precision and very limited range and which is used to calibrate the grade sensor or tilt sensor, which has a broader range, but is less precise.
It is the objective of the present invention to create a construction laser, in particular a rotating construction laser, and a method for measuring the tilt of an axis of rotation of a construction laser that requires only one sensor for measuring the tilt of an axis of rotation of a means for generating a laser plane and which enables a user to measure the tilt of the axis of rotation with very high accuracy. Furthermore, the construction laser should be able to continuously generate a tilted laser plane without returning periodically to a level position.
This object is achieved by realising the features of the independent claims. Features which further develop the invention in an alternative or advantageous manner are described in the dependent patent claims.
The inventive rotating construction laser, in particular self-compensating rotating construction laser, comprises a base; a laser unit for emitting a laser beam rotating around an axis of rotation so that the rotating laser beam defines a laser plane, wherein the laser unit is built and tiltably arranged to the base in such a way, that the axis is tiltable in at least one direction; and a tilt sensor for measuring the tilt of the axis.
According to the invention, the tilt sensor is supported by a sensor platform being pivotable with respect to the laser unit around the axis between at least two defined pivoting-positions in such a way, that the tilt of the axis is measurable by the tilt sensor in the at least two pivoting-positions.
Therein, the sensor platform is a structure that carries the tilt sensor.
The device requires only one tilt sensor to accurately measure the tilt of the axis of rotation. This is achieved by measuring the tilt in at least two different positions and computing the effective tilt. Thereby errors are eliminated that may result from the tilt sensor, e.g. temperature drift or hysteresis error. The rotating construction laser according to the invention is less extensive regarding its design compared to other devices known in the prior art. Furthermore, it does not require the construction laser to return to the level position in order to re-calibrate the tilt sensor.
Exemplarily, the laser unit can be built in such a way, that the laser beam rotates around the axis with a rotational speed of at least 120 rpm, in particular at least 500 rpm, especially at least 1000 rpm.
The sensor platform—together with the tilt sensor—is pivotable between at least two defined pivoting-positions. A defined pivoting-position is a pivotal position which can be occupied by the platform and in which a tilt measurement is taken. This enables continuous measurements of the tilt of the axis of rotation. Thus, the tilt of the laser unit and the axis of rotation can be adjusted during operation. Furthermore, two positions of the at least two pivoting-positions may be diametrically opposite of each other relative to the axis. Thus, alignment errors of the tilt sensor relative to the axis of rotation can be computationally eliminated.
Therefore, the rotating construction laser may comprise a calculation unit being designed in such a way, that a tilt value for the axis is derived by considering a measurement taken by the tilt sensor in each of the at least two pivoting-positions. The calculation unit may also be designed in such a way, that the tilt sensor is calibrated, in particular re-calibrated, by considering a measurement taken by the tilt sensor in each of the at least two pivoting-positions.
In another embodiment, the sensor platform is pivotable with respect to the laser unit around the axis between at least three defined pivoting-positions, in particular between an uneven number of defined pivoting-positions. The average tilt may be computed taking into account the positions at which the measurements were taken.
The laser unit—as a means for generating the laser plane, can further include an axle that is concentric to the axis of rotation, wherein the sensor platform is pivotably mounted to the axle. The axle provides a means around which the sensor platform may be pivoted or rotated. It may also serve as an axle for another part of the laser unit.
In another embodiment two bearings are located between a sensor platform and the axle, wherein the bearings are arranged at a distance from another of at least one bearing width. According to this embodiment, the pivoting movement of the sensor platform is very stable with respect to the axis of rotation of the laser beam. Thus, the tilt sensor is always closely aligned with the axis of rotation—in the defined positions as well as during pivoting motion. This helps to reduce errors resulting from the pivotable mounting of the sensor platform to the axle.
A printed circuit board may be provided between the tilt sensor and the sensor platform. The tilt sensor may be connected to the circuit board, and the circuit board again may be connected to a control unit. This represents an efficient design for transmitting the signal output of the tilt sensor to the control unit.
In another particular embodiment, the tilt sensor is pivoted by an engaging pin that is provided on a rotating part of the laser unit. Thus, just one motor is required to rotate the laser beam and to pivot the tilt sensor.
The tilt sensor can alternatively be pivoted by a pivoting motor according to another embodiment of the invention. The pivoting motor may be switched by position switches. The position switches include a light emitting diode (LED) and a photo detector which are placed on parts that are moving relative to each other. The LED is placed at a defined position of the tilt sensor. If the photo detector detects a change in the light intensity, it will turn off the pivoting motor exactly at the defined position. Alternatively, the pivoting motor may be a stepper motor. The stepper motor is programmed to turn the sensor platform a predefined number of steps which corresponds to the distance between the defined positions. The counter of the stepper motor is reset by the position switches.
The tilt sensor may be an accelerometer. The accelerometer may be a part of an integrated circuit. Accelerometers have been shown to provide tilt measurements of very high accuracy.
Summed up, in other words, the construction laser according the invention, in particular self-compensating rotating construction laser, comprises a base; a means for generating a laser beam plane, wherein the laser beam plane is created by a laser beam rotating around an axis of rotation, and wherein the means for generating the laser beam plane are pivotably mounted to the base, wherein the means for generating the laser beam plane is pivotable relative to an X-axis and/or a Y-axis; and a tilt sensor for measuring the tilt of the axis of rotation. Therein, the tilt sensor is pivotable around the axis of rotation for measuring the tilt of the axis of rotation in at least two positions.
The invention also relates to a method for determining a tilt for an axis of rotation of a rotating construction laser, the rotating construction laser.
The rotating construction laser comprises a base; a laser unit for emitting a laser beam rotating around the axis so that the rotating laser beam defines a laser plane, wherein the laser unit is built and tiltably arranged to the base in such a way, that the axis is tiltable; and a tilt sensor for measuring the tilt of the axis.
According to the invention, the tilt sensor is pivotable with respect to the laser unit around the axis between at least two defined pivoting-positions. Furthermore, a measurement of the tilt is taken by the tilt sensor in each of the at least two pivoting-positions and the tilt value for the axis is derived by considering the measurements taken by the tilt sensor in the at least two pivoting-positions. Alternatively, the measurements taken by the tilt sensor in the at least two pivoting-positions may also be considered for calibrating, in particular re-calibrating, the tilt sensor.
Exemplarily, the two positions of the at least two pivoting-positions can be opposite of each other relative to the axis.
Furthermore, the tilt sensor can be pivotable with respect to the laser unit around the axis between at least three defined pivoting-positions, in particular between an uneven number of defined pivoting-positions. Hence, the tilt value for the axis can be derived by considering a measurement taken by the tilt sensor in each of the defined pivoting-positions.
For example, the laser beam of the construction laser rotates around the axis with a rotational speed of at least 120 rpm, in particular at least 500 rpm, especially at least 1000 rpm.
Hence, according to this method, the tilt of the axis of rotation can be measured with a tilt sensor at a main position of the tilt sensor and at least one other position of the tilt sensor, wherein a compensating value can be generated out of the tilt measurement at the other position to adjust the tilt measurement of the tilt sensor at the main position.
The tilt sensor may be pivoted between at least two defined positions. Preferably, the two positions are opposite of each other relative to the axis of rotation.
According to another particular embodiment, the tilt sensor is pivoted between an uneven number of defined positions. The results of the tilt measurements at the defined positions can be advantageously used to calibrate the sensitivity of the tilt sensor.
The invention will now be explained in detail by referring to exemplary embodiments that are accompanied by figures, in which:
In
At the lower end 6 of the axle 5, a tilt sensor 19 is provided. The tilt sensor 19 is mounted to a sensor platform 20 using a printed circuit board 21. The sensor platform 20 is pivotably mounted to the axle 5 using two bearings 22, 23. The bearings 22, 23 are spaced apart at a distance D of one bearing width. Thus the sensor platform 20 and the tilt sensor 19 may be pivoted around the axis 18 of rotation. The distance D between the bearings 22, 23 stabilizes the pivoting movement of the tilt sensor 19. The tilt sensor 19 is aligned with the axis 18 of rotation. In order to achieve this alignment, the interior surface 24 of the sensor platform 20 is preferentially parallel to the axis 18 of rotation and also perpendicular to a mounting surface 25 to which the printed circuit board 21 is attached. To further stabilize the pivoting movement of the tilt sensor 19, a counter weight 26 is provided directly opposite of the tilt sensor 19 on the printed circuit board 21. In particular embodiments, the counter 26 weight may be replaced by second tilt sensor. This second tilt sensor may be used parallel to previous tilt sensor 19 or as a backup. The tilt sensor 19 is configured to measure the tilt of the axis 18 of rotation relative to the X-axis and the Y-axis. In a particular embodiment, two tilt sensors may be provided on the sensor platform 20, wherein one tilt sensor measures the tilt of the axis 18 of rotation about the X-axis and the other tilt sensor measures the tilt of the axis 3 of rotation about the Y-axis. These two tilt sensors may be arranged at a right angle to each other relative to the axis 18 of rotation.
The sensor platform 20 is pivoted by a pivoting motor 27. The pivoting motor 27 is a direct current (DC) motor. A pinion 28 is mounted to the drive shaft 29 of the pivoting motor 27 and is engaged with an external tooth system 30 on the sensor platform 20. On the bottom side 31 of the sensor platform 20, a pin 32 is provided to restrict the pivoting movement of the sensor platform 20. The pin 32 engages with stops 33 that are provided on two defined diametrically opposite positions 54, 55 (see
A main printed circuit board 35 is mounted to the lower end of the axle 5. Attached and/or connected to this main printed circuit board 35 is a control unit 36, the laser diode 9, the pivoting motor 27 and the tilt sensor 19 (via wires 37 and the other printed circuit board 21).
Two leveling arms 38, 39 that are perpendicular to each other are attached to the stopping disc 34. The leveling arms 38, 39 are provided with leveling pins 40, 41 that engage with leveling drives for tilting the laser unit 3 relative to the X-axis and the Y-axis. The leveling drives are not shown in the figures.
At start-up, the tilt sensor 19 is pivoted into one defined position that is the main position 54 (see
The stopping disc 34 is shown in
In a particular embodiment, a magnet 53 is integrated into one of the stops 33 to attract the pin 32. Once the pin 32 is attracted, the pin 32 is held at the stop 33. It is no longer required to generate a torque with the pivoting motor 27. When the sensor platform 20 is pivoted, the motor force overcomes the magnetic force and moves the sensor platform 20 into the other defined position 55. A constant force is applied by the pivoting motor 27 to hold the sensor platform 20 in that defined position 55 until the tilt measurement is completed. Then the pivoting motor 27 pivots the sensor platform 20 back to its main position 54 where the pin 32 abuts against the magnet 53.
In
In these embodiments, the stepper motor 27 and the position switching system 61 replace the pin 32 and the stopping disc 34 of the previous
The defined positions 54, 55 into which the tilt sensor 19 may be pivoted may be exactly opposite of each other relative to the axis 18 of rotation as shown in
In the embodiment of
The sensor platform 86 is pivoted by a pivoting motor 87 that is mounted to an arm 88 that is provided on one side of an axle 89 at midsection.
The sensor platform 86 is mounted to the axle 89 via two radial bearings 22, 23 which are kept apart by two bushings 90, 91 that are contacting the outer and inner rings of the bearings 22, 23. The bushings 90, 91 are of slightly different lengths. The bearings 22, 23 at the upper end 92 and at the lower end 93 of the axle 89 are held by wave springs 94 and retaining rings 95 which are placed in grooves. The wave springs 94 bias against the inner rings of the outer bearings 16, 23 to create a preload on the bearings 15, 16, 22, 23.
A tilt sensor 96 is aligned with the axis 18 of rotation. An interior surface 97 of the sensor platform 86 is advantageously arranged to be parallel to the axis 18 of rotation and is machined to be perpendicular to a tilt sensor mounting surface 98.
Referring now to
In another embodiment, the control unit 110 is configured to lock the mechanical actuator 107 into the engaging pin 106. The direction of turn of the rotating motor 102 may be reversible to pivot the tilt sensor 109 into a defined position 54, 55 and back again. After each pivoting movement the mechanical actuator 107 is disengaged from the engaging pin 106 by the control unit 110. Afterwards the speed of the rotating motor 102 returns to normal operational levels of several thousand revolutions per minute in order to generate the laser plane.
At the lower end 111 of an axle 112, a ball joint 113 is provided for pivotably mounting the laser unit 114 to a base 115.
Winistoerfer, Martin, Koleszar, Christopher
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